Straight Cutting Guidance?Wakeboard SPeaker Case

frankthetank

I have a set of wakeboard speakers similar to these pictured. you can ignore the tube bracket portion as it's not going to be used.

They are very deep welled(maybe 9 inches or so). I want to cut a few inches off the well/enclosure and then just epoxy bond it back together just to shorten the depth.

Any suggestions on getting a straight/flush cut so there are no/minimal gaps when placing back together?

The only power cutting tools I have are radial saw, scroll saw, jigsaw, oscillating tool, and a dremel with cutting bits. The rest are just hand tools, hacksaw, dovetail saw, carpenter say, tiny coping saw.

Any suggestions on how to straight cut it?
thanx:-)

Attached Images

wakeboardspeaker.jpg (17.8 KB, 0 views)

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gornoman

If the enclosures were cylinders it would be a straightforward operation, but since they are tapered removing any depth will leave you with mismatched sections.

Morgan44

Yep, And I'm far from an expert but I think changing the enclosure size by much will affect performance.

frankthetank

Not an issue with the mismatch...the way it is being applied....there will be spacers in a sense once I am done. Same goes for performance..

So I just need suggestions for cutting it straight at least:-)thanx

Nifrost

The mismatch that Gornoman mentioned will cause the gaps in the new seams (that you are trying to avoid). With the housings being tapered like they are it will be dang near impossible to not have gaps even with a perfect cut.

If it were me, I'd measure back from the speaker grilles several times around the diameter of the cone and mark the cut line. Then I'd connect my marks and make my cut with whatever tool I could control the best.

Once your cuts have been made, I'd try to "weld" the new seam back together using a soldering iron and the excess plastic as the filler material. If it wouldn't "weld", I'd use a hot glue gun. Either method should fill the gaps appropriately if you take your time.

Epb

Assuming the grill face is square then why not use 2 squares and make several marks. The other way is to use a cup that slips over the cone to the depth you desire and mark then cut....this though will require the cone itself to be a continuous slope from the face...

Attached Images

20160220_173028.jpg (777.9 KB, 0 views)

frankthetank

I am thinkin about placing the enclosure upside down on flat/level surface. Picture upside down cup. Clamp it to the table.

Mark where I need my cut. Then lay some 1 inch aluminium square tubing on the table maybe stack 3 or 4 of them (3 or 4 inch high cut) then place a penny or a nickel on both ends of the tubing then place 1 more piece of alum tubing on it.

Then I have a "track" for the saw blade. and just cut and turn the speaker enclosure as I go.

That make sense...?I use the track method for regular straight cuts why not sideways for this haha

Epb

Yeah that can work too.

kgsc

Or just go buy a couple of Heineken mini kegs, consume the content and modify away

Muddog

You have the tool, the radial arm saw. It will give a square, straight cut.
Clamp a square to table against the fence, line your speaker face parallel to blade using square and cut em.